Sonic method for testing metal



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SONIC METHOD FOR TESTING METAL Filed Feb. 22, 1944 2 Sheets-Sheet 1 Fi l- 6'/ 38 S G AMPLIFIER CASE Il f h ',M

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Patented July 16, 1946 SONIC METHOD FOR TESTING METAL Thomas A. Read, Herbert I. Fusfeld, and Sumner W. Kitchen, Philadelphia, Pa.

Application February 22, 1944, Serial N0. 523,430

(Cl. i3-69) (Granted under the act of March 3, 1883, as amended April 30, 1928; 370 O. G. 757) 4 Claims.

The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment to us of any royalty thereon.

Our invention relates to the testing of metals and it has particular reference to methods for detecting ilaws, cracks and other defects in metal specimens.

Broadly stated, the object of our invention is to provide improved procedure by which the presence of internal flaws in metal specimens of various compositions and shapes may be detected positively, quickly and reliably.

A more specic object is to make special adaptation of our improved testing method to the examination of metal specimens which are cylindrical in shape and non-magnetic in character.

Another object is to provide a method of testing the brass cases of fired and other artillery cartridges for the presence of dangerous season cracks.

A further object is to provide a reliable test for the susceptibility of fired and resized cartridge cases to splitting or other fracture on subsequent rering.

A still further object is to provide a test methodV by which it is possible prior to resizing to reject all cartridge cases which after being resized and reconditioned will crack on subsequent firing.

The improved metal testing method of our invention is predicated on our discovery that the damping characteristics of vibrated metal specimens will sharply reiiect the presence of internal iiaws if the specimen vibrations have such intensified amplitude as to set up in the metal peak stresses which are far higher than any heretofore employed by tests of the sonic character here considered.

In practicing our invention we attain the foregoing and other objects by exciting the metal specimen to longitudinal vibration at its natural or resonant frequency; by so building up the amplitude of this resonant vibration that the peak stress thereby induced in the metal has an exceedingly high intensity (of the order of ve to ten thousand pounds per square inch for brass cartridge case metal); by measuring the damping capacity (i. e. the internal friction) at this high amplitude of vibration; and by comparing the observed measurement with known standards for purposes of classifying the metal in the specimen either as sound or as defective.

Illustrative embodiments of our improved testing method and of apparatus suitable for practicing same are shown by the accompanying drawings wherein:

Fig. l is a diagrammatic showing of brass cartridge case testing equipment which incorporates the principles of this invention;

Fig. 2 is an enlarged section view showing preferred mechanical constructions for Fig. ls case support and driving magnet;

Fig. 3 is a horizontal section on line 3-3 through the top plate and circular air gap of the driving magnet of Fig. 2;

Fig. 4 is a showing of further details of the strain gauge which is attached to the test specimen side Figs. 5, 6 and 7 are curves illustrative of certain principles upon which our improved test method is based;

Fig. 8 illustrates alternative forms which Fig. ls case driving source and amplitude measuring means may take;

Fig. 9 shows further variations of the basic system of Fig. 1; .and

Figs. 10, 11 and12 show alternative arrangements by which the amplitude of case vibration may be registered and measured.

THE TESTING APPARArtrs 0F FIGS. 1-2-3-4 In Fig. l we have shown our improved testing facilities as organized for detecting the presence of flaws in a brass cartridge case I5. For clarifying the description to follow it will be assumed that this case is designed for use in a mm. artillery piece. As the description proceeds it will become evident that other sizes and shapes of cartridge cases may be tested with equal facility, and that metal specimens of compositions other than brass and of shapes and contours other than represented at I5 likewise lend themselves to test by our improved flaw detecting method herein disclosed.

Essential elements of the equipment shown in Fig. 1 include: (ai) a case vibrating magnet M; (b) a source B-C of alternating current power for energizing a driving winding I6 oi the magnet; (c) apparatus including a strain gauge S for measuring the amplitude of vibration that is in duced in the test case I5; and (d) current and voltage measuring instruments A and V for giving the ratio of the driving power input to the strain gauge output.

THE CAsE DRIVING MAGNET The case driving magnet M has the construction best shown in Figs. 2-3. A central core I8 of magnetically soft iron is fastened to a lower plate IQ of the same material and substantially square in shape. Extending upwardly from each of the four edges of this lower plate are side plates 2S, also of magnetic iron. Fitted into the square opening formed by the upper edges of these side plates is an iron top plate 2l having in its center a round Opening somewhat larger than the top of the central core I8.

The annular space between magnet core I8 and the surrounding plate metal 2| constitutes an airl gap through which a direct current winding 24 causes te flow unidirectional magnetic flux from the central core I8 in all radial directions to the surrounding top plate 2l. This core Winding 2li is continuously excited by any suitable source of direct current, designated in Fig. 1 by the termi-` nal iand Energizing leads 25;?5 are brought from winding 24 to the outside of magnet M in any suitalole manner suchv as that indicated in Fig. 2, i

The outside diameter of the magnets central core I8 is slightly less than the inside mouth diameter of the cartridge case l to be tested, while the inside diameter of the central opening in the magnets top plate 2l is somewhat larger than the mouth diameter of the same case. This permits the case mouth to ht down into the magnets annular gap in a manner clearly indicated by Figs. 1-2-3 and to a depth of slightly over 11/2 inches. In this position there is passed through the ease mouth metal the radial magnetic flux earlier referred to as being set up by direct current winding 2li. Preferably this unidirectional magnetic force has an intensity of the order of 10,000 oersteds.

Positioned between the case mouth metal'and the-magnet plate metal 2| is the alternating current driving winding I5 earlier mentioned. Preferably this winding takes the form of the represented single turn of copper strip 'secured inside the opening in plate 2l in any suitable manner such as shown in Figs.- 2-3. There thin layers of insulation 28 separate the copper strip I5 from the. plate metal and at the same time mechanically support the Astrip through a bonding thereof to the metal 2 l For holding the cartridge case I5 in the represented test position use may be made of any suitable means which impart mechanical support without interfering with case vibration. Such means may take the form of a support plate 33 held at suitable distance above the top of magnet M Iby corner uprights 3d and having a central opening somewhat larger than the outside diameter of the cartridgey case VHi. Two or more strands of piano wire 3l are stretched at moderate tension across this opening between securing screws S2. By restraining downward movement of the case head rim, these wires 3l mechanically suspend the case in the test position represented.

SUPPLY or' CASE DRIVING ENERGY For causing the just described magnet M to drive the cartridge case i5 at its natural rate of vibration use is made of the facilities which the left portion of Fig. i represents. These facilities include the earlier named source B-C of alterhating current power plus a step down transformer T, a capacitor 36, the vearlier mentioned amine-ter A and a frequency meter F.

Source B-C may take any suitable form capable of supplying up to about one kilowatt of power at a frequency which exactly matches the natural or resonant rate of longitudinal vibration for the cartridge case l5. Cases ofthe 75 mmf size here' 4 described are found to have a natural vibration frequency of the order of about four thousand cycles per second, and in conducting tests on such cases source B-C thus should be capable of supplying case driving energy at four thousand cycles per second and further be adjustable through one or two hundred cycles above and below the stated value. The utility of this adjustment will Ibecome further evident as the description proceeds. The step down transformer T is for the purpose of converting alternating current energy of the moderate-voltage potential readily availalble at source B-C into energy of the lowered voltage and relatively high amperage which is required for satisfactory operation of the case driving magnet M. In one design which has proven satisfactory this transformer makes use of a primary having 8S turns of No. 18 wire wound in two layers on an insulating tube about 8 inches in diameter, and having a secondary made up of a single copper strip 2 inches lv'v'ide by .020 inch thick wound as a single turn around the same tube. The particular transformer used is of the air core type.

This copper strip of 2 inches by .020 inch cross section is, in the test equipment now described,

continued from the transformer T into the air gap of the driving magnet M where it constitutes the single turn driving winding shownV at I6 in Figsv 2 3. For producing `cartridge case vibrations of the elevated order required by our test method currents of the order of several hundred amperes are supplied .by the secondary of this transformer T.

The load thus presented to the power source B--C is found to be predominantly inductive, and without corrective means results in an objectionably low power factor. To compensate for this use is made of a capacitor 35 series connected in the transformer primary `circuit as shown in Fig. l. By choosing the capacitive rea'ctance of element 3S to equal the inductive reactance of transformer T and its connected load, the power factor of energy drawn from the alternating .current source B-C may be made substantially unity. Under these conditions the driving magnet M is observed tol impose a load on the source B-C which approximates a pure resistance of about 12 ohmsi Y The described magnet M and energizing sources therefor constitute an eddy current metal drive by which there is exerted on the case mouth mechanical forces which alternately act upwardly and downwardly This action results from the fact that the alternating 4current in the driving winding l5 induces corresponding` eddy currents in the case mouth metal. The interaction of these induced eddy currents with the radiallyflowing unidirectional magnetic flux produces on the case mouth metal an alternating mechanical force which is 4directed along the axis of this case.

This alternating mechanical force reverses its direction in step with the frequency of the current from driving source B-C, and when the frequency thereof is chosen to match the test cases natural frequency of vibration there may be produced in the case longitudinal vibrations of the extremely elevated magnitude which the test method of our invention requires.

Since the case driving forces are directed alternately in opposite directions at a frequency having the stated value of around four thousand cycles per second, the average force of each of.

these complete cycles is zero and this makes it possible to support the case in a position in the THE AMPLITUDE MEASURING MEANS For measuring the amplitude of the mechanical vibrations thus induced in the test case I use i's made of the earlier named strain gauge S plusv an amplifier 38 plus the earlier named voltmeter V. 4

As is more clearly shown in Fig. 4, the strain gauge S consists of a series of back and forth loops of electrical resistance wire 4!) mechanically bonded together by suitable insulating material and further bonded to the wall side of the cartridge case I5 under test. As a result of this bonding any change in the length of the test metal I5 produces a corresponding changeV in the mechanical length of thegauge loops 40.

These loops are connected in series and the resistance variations of each which accompany changes in its effective length are additively com-V bined to give a total resistance change which lends itself to ready measurement or detection. Strain gauges of the type shown at S are commercially available, and one design found especially suitable has a static resistance of 500 ohms and a strain sensitivity of 3.5. By strain sensitivity is meant the ratio of the fractional change in resistance of the gauge to the fractional change in gauge length.

For most effective response to longitudinal vishould be attached at some intermediate point between the two case ends, such as is sho-wn in Figs. 1 2. This particular location was selected after experimentation which showed that in lon gitudinal Vibrations of the character here considered the effect is analogous to simple compression and stretching from the two case ends. This results in a point known as the displacement node, at lwhich mechanical movement of the case divides and further at which there is no change of mechanical position.

For cartridge cases of the 75 mm. design shown, this point is approximately one-third of the case length distance from the head end. Mounting of the strain gauge S at this point results in the maximum movement between the two gauge ends; and while other positions are found also to give indications of the case vibration amplitude their effect is relatively less than the nodal point mounting here shown.

For converting variations in strain gauge resistance into corresponding variations in potential, use is made of a battery or other direct current source 42 of constant potential connected through the strain gauge loops 40 in series with a resistor 43.

As long as the strain gauge remains static the current flow through resistor 43 is constant and the voltage appearing thereacross remains unchanged. Each decrease in strain gauge resistance which accompanies an effective compression of the cartridge case I5 raises the resistor current and produces a corresponding rise in voltage between the resistor terminals. Similarly, each increase in strain gauge resistance which accompanies an effective stretching of the test case I5 produces a corresponding drop in resistor current and a resultant lowering of the resistor terminal voltage.

The magnitude of these changes in resistor voltage is relatively small and in order to increase it tosuch an extent as to make ready measurebration of the test case I5 the strain gauge S 6a ment possible use is made ofythe amplifier' 38. Thisamplier may be any one of a number of commercially available forms, and for this reason no attempt to show details has been made.

Exciting its input terminals is the potential appearing across the resistor 43. .Each change therein is magnied many times by the amplier and impressed upon a suitable measuring device indicated as voltmeter V.

When-appropriately calibrated, this voltmeter can thus be made to yield a direct indication of the amplitude at which the cartridge case I5 is being vibrated yduring practice of the improved test method of our invention. Conveniently this indication may be in terms of the millivolts of potential which appear across resistor 43, and in connection with certain test data later presented use is made 0f a voltmeter indication expressed in such terms.

The combination just described is thus so or- OPERATION oF THE FIG. 1 TEST EQUIPMENT In applying the just described test equipment of Fig. 1 to red l5 mm. brass cartridge cases we are able to predetermine with high accuracy all of those cases in the tested group which will rupture upon resizing, reloading and subsequent firing, and which of the cases in the group will withstand the rering without rupture or other failure of the case metal.

The need for such determination has been felt in a practical way for a long time. Splits which have been obtained in the firing of resized brass cases are now ascribed to the presence of season cracks. These cracks are caused by the attacks of the products of the burning of the propellant powder during the period between the ring of the round and the cleaning of the case.

Such cleaning is subject to considerable delay by reason of the fact that in many instances the cases lay out in the eld exposed to weather for long periods of time after their original iiring, and when subsequently subjected to resizing operations preparatory to a second use there frequently have developed minute cracks, :particularly on the side Wall interiors. y

These are so'inconspicuous and diflicult to detect that they go completely unnoticed through the entire sequence of resizing operations and are only discovered upon reiiring of the case, when their presence then results in longitudinal splits or other failure of the case. Such failures not only endanger -personnel ring the weapon but by reason of loss in chamber pressure they so alter the 'ballistic performance of the fired projectile that aiming becomes inaccurate and unreliable. In addition the escaping gases erode the weapons chamber and firing pin causing early malfunction of the weapon.

Until the advent of our invention, no method was available for reliably separating the good from the bad prior to case resizing or at any time prior to case reuse. With our method, however, the desired selection can be made quickly, reliably and effectively.

In Vusing the earlier described equipment of Fig. 1 each of the cartridge cases to be testedis-A .tabacco subjected to onlytwo preparatory operations. The primer is punched out of the case head, .and the mouth of the case is restored substantially to its original circular shape. l

. So prepared the case then is lowered through the opening Vin the support `plate 33 (see Fig. 2) to the `represented position where thewall Vmetal of the case mouth ts into the `annular gap of .the driving magnet M and is there supported by a resting of the case head rim on the supporting wires 53|. The strain gauge S is now attached to the case side wall at the location between the two ends f thev case determined as earlier described.

- Direct current is now applied to the magnetMs central core winding 2e, and alternating current from source B-C is applied to transformer T and thence tothe case driving winding IS. ri'his direct current supply is adjusted to a value predetermined as suitable for the test and which yields the required intensity of uni-directional flux in the circular gap surrounding the magnets central core head I8.

The frequency of the alternating current from source B-C is, by the aid of meter F, roughly adjusted to what is expected will match the resonant frequency-of vibration for the case I5. An observation at meter V of the resulting amplitude of case vibration is taken, and holding the case driving current as shown by meter A at a constant value, the frequency of the alternating driving current is varied'in small steps in both directions `until .the amplitude meter V shows a maximum reading.

This maximum indicates that the frequency of the alternating driving current now exactly matches the resonant frequency of vibration for the test case i5. This indication follows from the well known resonance curve illustrated in Fig. 5 which shows how the test case I5 responds in vibration amplitude to driving current frequencies above and below the resonant value which the dotted vertical line designates.

Explanation has already been given of how the eddy 'currents induced in the case mouth metal interact with the uni-directional flux iiowing through lthat metal to set up in the metal mechanical forces which alternately act upwardly and downwardly instep with the reversals of current induced in the case mouth metal. of the order of four thousand cycles per second the duration of each of these forces is extremely short. Each upwardly acting force pulse tends to compress the side wall metal above the case mouth, while each downwardly acting force tends to stretch or elongate it.

The inertia of the total case mass prevents the complete case from following these pulsations, andv even though applied at one end only their effect is to set up longitudinal vibrations toward and away from an intermediate nodal point along the case length. Were both ends of a, simple vcylindrical test specimen to be open this point would `be substantially midway. Closure of the top end by the case head shifts this neutral point upwardly to about two-thirds of the total distance from the case mouth.

Our observations show that at resonant frequency for Vthe case each compressive action in the case side wall below the nodal point is accomthat each side wall stretch or elongation below the nodal point ls also accompanied by corre- At frequencies 8 spending elongation in the side wall metal dabove the nodal point.

During resonant vibration, therefore, a simple bellows action takes place wherein the case metal at the nodal point and on both sides thereof (with the exception of the case extremities) alternately shortens under compression and lengthensr under tension. Although the nodal point completely lacks longitudinal motion, some transverse expansion and contraction of the case circumference appears there to be present.

For the relatively low intensities of induced case vibration which have heretofore been used in attempting to test material specimens, it is observed that a defective specimen exhibits practically the same damping capacity as does a sound specimen. In the curve of Fig. 6 such relatively low vibration amplitudes are indicated by the vertical line 45, and typically they have resulted in peak stresses in the test metal of the order of five hundred pounds per square inch or lower. y

We have discovered that when the amplitude of the longitudinal test case vibrations is increased to a substantially higher value, such as is designated at 46 in Fig. 6, a defective case will show a substantially higher damping than does a sound case. By damping is meant the internal friction of the case metal, and one convenient measure thereof is given by the ratio of the case driving force to the resulting vibration amplitude as indicated through the strain gauge S by Fig.

is voltmeter V. During the remainder of this description a quantity proportional to that ratio will be designated as the sonic test coefficient.

Observations made by us show that a sound test specimen has a damping-amplitude curve of the relatively flat character shown at 41 in Fig. 6; thatspecimen metal having defects of moderate quantity has a relatively steeper curve such as is shown at 48; that the presence of fewer defects causes the curve to be less steep, as shown at 49; and that defects present in larger number result in a curve of the greater steepness shown at 50.

Accordingly, in operating the Fig. 1 equipment the driving current supplied from source B-C to the magnet winding I6 is next increased to such an extent that the resulting resonant vibration of the test case l5 rises to an amplitude of the high order shown at 46 in Fig. 6.

That high order amplitude is known to be attained when meter V gives a reading corresponding to about 12 millivolts input to the amplifier. It is accompanied by peak stresses in the case metal of the order of from live to ten thousand pounds per square inch. Correlation of the readings of meter V' with such stresses can be made in any one of a number of manners so well known to the metals testing art that description at'this point isdeemed unnecessary.

At these high stress amplitudes of longitudinal vibration there is a relatively wide variation in the damping capacities of sound and defective cartridge cases. As Fig. 6 indicates, the greater the defects the higher the damping and hence the more driving force that is required to induce the high vibration amplitude.

Since for a given Vibration amplitude there is a more or less direct relation between the specimen damping and the driving power requirements, those cartridge cases which are defective require considerably more power from driving source B-C than do cases which are sound. One measureof this power is the reading of ammeter A. It is found that the impedance of the case;

' driving circuit remains substantially constant rev9 gardless of whether the case is sound or defective, and for this reason the reading of ammeter A may be assumed to be directly proportional to the driving power input.

ANALYSIS oF TEs'r RESULTS In order that some variation in the values of test vibration amplitude may be permitted, we prefer to analyze comparative test results through a ratio earlier termed as the sonic test coefficient. This coecient is the quotient of the ampere current reading by meter A to the millivolt potential appearing across resistor 43 as read by meter V. For test system constants having one particular set of values, new o-r sound cases exhibit a coeiiicient value of approximately 0.30; fired cases having defect contents within tolerances acceptable for retiring show coeicients of 0.50 and below; and fired cases having defects suiiicient to cause rupture after resizing and subsequent firing have test coefficients above 0.50.

This relation is best indicated by the curve of Fig. 7 wherein the horizontal dotted line indicates the point at which acceptable cases should be separated from unacceptable ones on the basis of proven test results.

One set of data which establishes the foregoing sonic test correlation is presented by the accompanying Table X.

TABLE X Some test correlation Sonic test Firing Sonic test Firing Cabe coeicient result Case coefficient result 161 0. 368 0 202 0. 760 :I: 166 400 0 200 778 0 108 400 0 102 779 0 79 417 0 127 784 x 116 433 0 115 796 158 437 0 204 800 17 205 442 64 804 I 153 450 0 169 825 O 117 450 0 137 842 m 7 C 451 0 150 847 z 159 460 0 129 850 I 111 467 0 160 886 100 468 0 66 888 a: 131 500 0 62 919 I+ 165 500 0 77 933 -I- 171 516 0 67 940 z 106 544 0 125 952 x+ 120 550 a: 141 955 I 101 568 1: 172 989 151 577 I 206 990 0 103 591 0 121 1. 02 z 201 592 0 126 1. 14 :t-l- 208 616 :t 136 1. 32 :t-I- 162 636 0 140 1. 33 :r 74 650 x 122 1. 35 :L 119 651 0 173 1. 37 0 170 659 0 134 1. 38 :t 112 660 0 130 1. 44 71 661 z 138 1. 50 z 73 666 139 l. 60 :l: 167 668 0 132 l. 60 z 164 676 I 135 1. 64 I+ 81 679 -i- 168 2. 00 :c+ 156 685 1 114 2. 35 i- 203 705 0 72 2. 66 I+ 133 708 0 68 4. 00 I+ 157 728 I+ k70 5. 34 I+ 123 7 54 I O-No defect.

x-Longitudinal crack. -I--Tran sverse rupture.

The seventy-five red brass cartridge cases of 75 mm. size which are identified under the case column were examined for the presence of season cracks by our improved sonic test method. This examination gave the sonic test coefcients which Table X lists. These eases were then fired at 12% excess pressure in a 75 mm. weapon having a worn chamber. 53% of the cases split. None of the cases with a sonic test coeicient less than 0.55 split. All but one of those with. the coefficient above 1.00 failed during firing.

' function as does the Fig. l source.

10 This data shows an excellent correlation between the sonic test coefiicient and the incidence of ring splits. The high percentage of splits in the group was a result of its selected components for it was expected that most of the cases with a coemcient above 0.50 would split.l f

THE MODIFIED TEST SYSTEM 0F FIG. 8

In Fig. 8 we have represented alternative forms of case driving power supply and of vibration amplitude measuring means. These diier from the corresponding elements earlier described in connection with Fig. 1 in the manners now to be pointed out.

Look first at the case driving power supply means of Fig. 8, it makes use of a power amplier 53 and a driving oscillator 511. This oscillator must be capable of generating a frequency which matches the resonant vibration frequency of the test case I5 and should in addition be adjustable through a small range on either side of theresonant value. It feeds into the power amplifier 53.

This power amplifier 53 corresponds to the source B-C of Fig. 1 and should have an output capacity of approximately one kilowatt; in energizing transformer T it performs exactly the same In this Fig. 8 arrangement adjustment of the power driving frequency, as measured at meter F, is eifected at the driving oscillator, while adjustment of the driving power current, as measured by meter A, is effected at the power amplifier. Both of these adjustments are manual and are made to meet the requirements earlier described in connection with Fig. 1.

Looking next at the frequency amplitude measuring means of Fig. 8, these employ a tuned-plate amplifier 56, a cathode ray oscillograph 51, a beat frequency oscillator 58, a potential comparing device 59 and a transfer switch 60. I

In order to obtain an amplitude measurement for the vibrating case I5, switch 60 is first thrown to the upward position wherein its output circuit feeds into resistor 43 and the tuned-plate amplier 55. That amplifier is manually adjusted for the resonant case frequency, and under these conditions it functions to magnify the voltage fluctuations across resistor 43 which the strain gauge S produces. y

So magnified, these fluctuations aretransmitted to the cathode ray oscillograph 51 where they cause to be traced on the oscillograph screen (not shown) a visual showing of the case vibration wave form and amplitude. In the system of Fig. 1 only the latter quantity can be indicated. The former occasionally is of value and can be providedby the Fig. 8 arrangement,

The amplitude of the case vibrationwave having been noted on oscillograph 51, transfer switch 60 is shifted to the downward position where the amplifier 56 has transmitted thereto comparison oscillations from the beat frequency oscillator 58. This oscillator is manually adjusted to the resonant frequency of the test case I5 and it causes oscillograph 57 to trace a wave of the same frequency as is present in case I5.

The amplitude of this wave as show by the oscillograph may be varied by device 59. Adjustment from that device is now so made that the wave traced by oscillograph 57 has the same amplitude as did the wave there traced when amplier 55 was connected with the strain gauge S.

Under these matched wave conditions the voltage reading at indicator V of the comparing ll device 59 is now noted. This reading corresponds to that directly obtained by voltmeter V in the organization of Fig. 1.

For purposes of computing sonic test coeicients the modied organization of Fig. 8k thus is the full equivalent of the basic organization shown in Fig. 1.

THE REGENERATIVE ORGANTzATroN or FIG. 9

It has been seen that Fig. 8s driving. power supply facilities require that the frequency of the supplied driving power be adjusted at oscillator 54 to match the resonant frequency of the tested case I5. The need for such manual adjustment may be dispensed with through use of driving power equipment organized as shown in Fig. 9.-

There Fig'. Ss driving oscillator 54 is replaced by a phase shifting network 62. The input terminal's of this network are directly connected with the output terminals of an amplifier 'I2 having automatic volume control, while the output terminals of phase shifter 62 lead directly to the input terminals of power amplier 53.

The power ampliiier 53 of. Fig. 9 corresponds to the similarly identiiied amplifier of Fig. 8 and constitutes the source of alternating current drive energy impressed upon transformer T and thereby transmitted to the driving winding I6 of magnet M The strain gauge ampliner `33 of Fig. 9, in turn, corresponds in all respect to the similarly marked amplier of Fig. 1 and indicates the strain gauge output at meter V.

In operation ofthe Fig. 9 system, each vibration of the tested case I varies the resistance of strain gauge S, produces a corresponding change in the voltage across resistor 43, causes an ampliiied measure of this change to appear at the output terminals ofV amplier I2 and hence at the input terminals of phase shifter 62. There such displacement and timingV s introduced as proves most effective for exciting the power amplier 53. Since this excitation is in the form of pulsations which recur at the cases resonant frequency, the cycles of case vibration once set up are self-propagating through a feed back or regenerative action.

Once, started, this action continues indenitely and it automatically adjusts the frequency of the case driving voltage from amplifier 53 to an exact matching relation with the resonant frequency of the vibrated case I5.

In order to start this regenerative vibration control, it is merely necessary to set up some electrical or mechanical disturbance, such as closure of a switch 64 in the supply circuit for the magnets direct current winding 24. Once the sequence of regenerative actions above discussed, has been started, these actions `continue until some break is made in the power supply or feed back circuits.

The automatic volume control desired in amplier 'I2 is such that oscillation of the system in the manner described above is possible when the sonic test coeinicent of the cartridge case is substantially above the acceptance value; it further is such that the amplitude ofV oscillation is successively greater for cases of lower sonic test coefficients until the maximum permissible power from amplifier 53 is attained for a case with a test coeicient below the acceptance value, such as 0.30.

THE ALTERNATE AMPLITUDE INDICATORS or' F1os. 10-11-12 In all of the thus far shown arrangements for indicating vibration amplitude', use has been made of the strain gauge S earlier described as. being mechanically attached to the case side wall and varying its resistance in step with the elongations and contractions o the side wall metal. While exceedingly satisfactory such a strain gauge is not, however, the only device which lends itself to registration of amplitude measurements.

During its vibration, a min. case emits a highly audible sound, and the intensity of this sound has been observed to vary in direct proportion to the amplitude of the vibration. In the arrangement of Fig. l0 advantage of this fact is taken by the use oi a microphone 3G placed to receive the sound waves induced by the longitudinal vibrating movements of the case.

This microphone 65 may be of the conventional carbon-granule type used in commercial telephones, or the condenser type used in radio broadcasting, in which case itr sets up resistance variations analogous to those produced by the strain gauge S. This similarity makes possible a direct substitution in the electrical circuits of Fig. l, for example, of the microphone 66 for the strain gauge S and results in the apparatus organization which Fig. l0 shows.

The organization of Fig. 10 employs battery 52 in the same manner as does the strain gauge S of the earlier Views. It is possible to eliminate this battery by employing a dynamic type of microphone in the manner shown at 57 in Fig. 1l. Such a device generates its own potential and for this reason is suitable for directly exciting `the ampliiier 38 without recourse to the earlier shown battery 42 and resistor 43.

Fig. l2 shows a further arrangement for converting the case vibrations into amplitude proportional changes in potential and supplying that potential to amplifier 33. In Fig. l2 use is made of an electrical pick up device 63 analogous to that used in phonographs. Such. a device 69 also generates its own voltage and hence is suitable for direct connecting to the input terminals of amplifier 3.8.

It should be pointed out that test specimens which vibrate. at above the audible sound range may also have their vibration amplitudes detected by the just described apparatus of Figs.A 10-11-12.

SUMMARY From the foregoing it will be seen that we have provided improved procedure by which the presence of internal flaws in metal specimens may be detected reliably, quickly andeasily; that we have made special provision for examining metal specimens which are cylindrical in shape; that we have provided a method for testing the brass cases of red artillery cartridges for the presence of dangerous season cracks; that we have developed a reliable test for the susceptibility of fired and resized cartridge cases to splitting on subsequent rlring; and that we have perfected a test method by which it is possible prior to resizing to reject all cases which after being resized and reconditioned willfracture on firing.

The testing yapparatus for '75 mm. cartridge cases which we have shown by way of illustration may with very slight modication be adapted to the testing of artillery cartridge cases of other sizes and forms. Such adaptation consists in selecting mechanical dimensions of the case supporting frame and the driving magnet M to accommodate the particular size of cartridge case desired to be tested, and in choosing electrical characteristics of the driving power supply and vibration measuring facilities which are appropriate for the selected case size.

Our improved sonic testing method further lends itself to use with metal specimens other than cartridge cases and may with comparable success be applied to the detection of internal ilaws in cylindrical specimens which are open at both ends.

Nor are cylindrical specimens the only type which can be tested, for upon the making of modications immediately apparent to those skilled in the art, specimens of other forms and shapes may also be subjected to flaw determination tests by the here disclosed method of exciting the specimen to resonant frequency vibration at amplitudes sufliciently intense to reect specimen iiaws, measuring the sonic test coefficient under these conditions and comparing the observed value with standards established for specimens of the same form and material.

Our inventive improvements are therefore eX- tensive in their adaption and are not to be restricted to the specic form here disclosed by way of illustration.

We claim:

1. In a method of testing metal for the presence of defects, the steps which' comp-rise exciting a specimen of said metal to longitudinal vibration, adjusting the frequency of this longitudinal vibration to the specimens natural frequency of resonance, measuring the amplitude of this resonant frequency vibration to indicate the resulting peak stresses which are set up in the specimen metal, intensifying this resonant frequency vibrations amplitude until said indicated peak stresses attain a predeterminedly high value at which a defective-metal specimen exhibits a damping capacity sharply differing from that of a sound-metal specimen, and measuring said damping capacity at the so intensied amplitude of vibration whereby to determine whether the metal of said tested specimen is sound or is defective.

2. In a method of testing a cylindrical specimen of cartridge case brass for the presence of defects, the steps which comprise exciting said specimen to longitudinal vibration, adjusting the frequency of this longitudinal vibration to the specimens natural frequency of resonance, measuring the amplitude of this resonant frequency vibration to indicate the resulting peak stresses which are set up in the specimen brass, intensifying this resonant frequency vibrations amplitude until said indicated peak stresses attain high values typied by several thousand pounds per square inch and at which a defective-brass specimen exhibits a damping capacity substantially different from that of a sound-brass specimen, and measuring the damping capacity of said tested specimen at said high stress producing amplitude for purposes of classifying the brass thereof either as sound or as defective to an observed degree.

3. In a method of testing metal for the presence of defects, the steps which comprise inducing in a specimen of said metal mechanical forces which repeatedly reverse themselves and by which said specimen is excited to longitudinal vibration, adjusting the frequency oi' this vibration to the specimens natural frequency of resonance, measuring the amplitude of this resonant frequency vibration to indicate the resulting peak stresses which are set up in the specimen metal, intensifying this resonant frequency vibrations amplitude until said indicated peak stresses attain a given high value at which a defectivemetal specimen exhibits a damping capacity sharply differing from that of a sound-metal specimen,v and measuring the energy that is required to produce said given-stress-valve amplitude of resonant vibration whereby to indicate the relative damping capacity of the specimen and therefrom to determine whether the metal of said specimen is sound or is defective.

4. In a method of testing metal for the presence of defects, the steps which comprise electrically inducing in a specimen of said metal mechanical forces which repeatedly reverse themselves and by which said specimen is excited to longitudinal vibration, adjusting the frequency of this vibration to the specimens natural frequency of resonance, measuring the amplitude of this resonant frequency vibration and the resulting peak stresses which are set up in the specimen metal, intensifying this resonant frequency vibrations amplitude until said measured peak stresses attain a given high value at which a defectivemetal specimen exhibits a damping capacity substantially differing from that of a sound-metal specimen, measuring the electrical energy that is required to produce the intensified amplitude vibration by which said given high value of measured peak stress is yielded, and dividing said given-value stress measurement into said electri- -cal energy measurement whereby to indicate the relative damping capacity of the specimen for purposes of classifying the metal thereof either as sound or as a defective to an observed degree.

THOMAS A. READ. HERBERT I. FUSFEID. SUMNER W. KITCHEN. 

